RML Lean Inc. LEAN Engineering Training Manufacturing

Definition:
There are many definitions of lean, lean principles, lean production and lean manufacturing. Lean manufacturing is a process management philosophy derived mostly from the Toyota Production System that is an ongoing evolution of solutions designed to achieve perfection. It is a whole systems approach way of thinking that creates a culture where everyone is continuously improving processes.

Lean is renowned for its focus on reduction of the original Toyota seven wastes to improve overall customer value. Most processes are loaded with waste including the waste of motion, transportation, processing, delays, overproduction, inventory, correction and intellect. The lean expert can see some form of this waste everywhere. They see it in manufacturing plants, hospitals, banks, grocery stores, department stores, schools and government offices. The waste is often so obvious it is hard to believe a profit could be made with such excess. The objective in lean is to identify, reduce and or eliminate as much wastes as possible. Once the waste has been removed, all that is left is value added activities defined as any activity that physically changes the form, fit or function of the product or service being provided to the customer or any action or process that a customer would be willing to pay for.

In the words of Toyota (often placed everywhere in their factories)
Job = Work + Kaizen (improve)
The more time spent solving problems and eliminating waste the more time can be reinvested in adding value to the customer!

Lean has its roots in manufacturing, however today the lean philosophy is being applied successfully to non-manufacturing organizations including healthcare, construction, financial, military, service, non-for-profit and many others.

The benefits of doing lean can be significant and in some cases unbelievable!

LEAN Tools Workshops:
• Introduction to Lean Concepts
• Lean Simulation
• Value Stream Mapping
• 5S, Workplace Organization & Visual Management
• Set Up Reduction - SMED
• Pull Systems - Kanban
• Lean Facilities Layout & Flow
• Total Productive Maintenance - TPM
• Kaizen Events
• Cell Design
• Takt Time and Operations Balancing
• Standard Work
• Level Scheduling
• Lean Assessment and Auditing
• Error Proofing
• Policy Deployment

Workshop Descriptions:

Certified Lean Practitioner:
A dynamic 5 day workshop designed to give students an in depth knowledge of the lean methodology and lean tools. This workshop will include lecture and hands on demonstrations and simulations conducted in a classroom setting. A passing grade on the final exam is required for certification.

Benefits:
• An excellent practical knowledge of the lean methodology and lean tools.
• Actively engage in continuous improvement activities at the workplace.
• Certification after completion.
• Excellent value at a reasonable cost.

Lean Master Certification:
In addition to successfully completing the Lean Practitioner Workshop, the student must also complete a pre-approved lean project or kaizen event that results in a process improvement with sustainable measurable results. A final report is required.

Benefits:
• You will be able to coordinate and lead process improvement initiatives and kaizen events.

Introduction to Lean Concepts:
A basic overview of lean history, methodology, tools and benefits of doing lean will be presented in a simple but real life format. We will discuss the need for organizations to change, the concepts of value and non-value adding and several examples of waste as they exist in the workplace. The lean tools will be introduced and we will discuss how to best apply them to support your continuous improvement initiatives. This class is offered with and without a lean simulation.

Lean Simulation:
People often learn best when they are able to see a demonstration of lean techniques in action. In conjunction with the Introduction to Lean Concepts class, we offer a hands-on lean simulation of a manufacturing, healthcare or office process in a class room setting. The class participants will run the 1st simulation in a traditional (non lean) setting. We get class input to make process improvements before running a 2nd simulation. We then apply the lean tools to make additional improvements for the 3rd simulation. Key metrics are kept for each simulation so we can do a final comparison. Unlike some of the complicated lean simulations offered by other consulting groups in which they own the simulation materials, our simulations are simple and are yours to keep.